Preface The service manual contains descriptions of maintenance essentials on BX125 motorcycle. Service data include attentions that shall be paid on all the maintenance operations in the service manual. Please read the manual carefully before operation. Check and adjustment contains statements on the main points of inspection and adjustment, safety of the vehicle, maintenance means of each component’s performance.
Service Data General Safety Maintenance Regulation Specification Sheet Fault Diagnosis General Safety Carbon monoxide (CO) When it is necessary to start the engine, please make sure the workplace is well ventilated. You shall never run the engine in an enclosed place. Attentions Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss of consciousness and even death.
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High-temperature Burn Pay attention to your safety during maintenance. Carefully, do not be burnt by the ghi-temperature engine, exhaust pipe, muffler and other hot parts. You should take care of each other in case of cooperation with others. Maintenance Regulations While repairing and servicing, try to use tools of metric system as possible as you can.
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While removing a component with many assemblies, do from outside to inside. Loosen firstly smaller assemblies. For the complicated assemblies, such as gearbox, keep them in a proper assembling order for the sake of easy assembly later. Pay special attention to the key fitting position before disassembly. The components that are not used any more shall be replaced on time before disassembly.
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Installation of rubber hose (fuel, vacuum, or coolant): insert its end into bottom of connector so that there is enough room for the hose clamp to grip the connector. Install the rubber or plastic dustproof boot back to its originally designed position. Disassembly of ball bearing: use a tool to push against one or two (inner and external) bearing races.
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Specifications (BX125) BX125 157FMI-C Model Engine type 2020 Fuel 93# unleaded gasoline Overall Length(mm) Number of Overall Width(mm) cylinders Bore*stroke 57.3 mm *48.4 mm Overall height(mm) 1105 Total 1320 124.8 Wheelbase(mm) Displacement Front 58kg Starting mode Electric shaft Rear Weight (kg)
Fault Diagnosis Hard to Start or Unable to Be Started Fault Diagnosis Adjustment Fault Cause Check whether the gasoline No gasoline in the gasoline tank pump works Oil tube blockage of gasoline tank injector normally Oil tube blockage of gasoline pump Adequate and smooth No gasoline Tube blockage of fuel tank evaporation...
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Inflexible rotation (low revolutions or powerless) Fault Diagnosis Adjustment Fault Cause Slowly start the engine Blockage of air filter Failure of gasoline Engine rpm Engine rpm Tube blockage of fuel tank cannot rise rises evaporation control system completely Blockage of exhaust pipe Failure automatic choke...
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Ignition time adjustment Failure of ECU Assembly Normal Abnormal Failure of trigger Adjustment of throttle adjustment screw Gasoline mixture is too thin (release screw) Proper Improper adjustment adjustment Gasoline mixture is too thick (lock screw) Air aspirated in gasket Failure of insulation pad Fixed nut of throttle is loosen No air Air aspirated...
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Fault Diagnosis Adjustment Fault Cause Ignition time adjustment Failure of ECU Assembly Normal Abnormal Failure of trigger Small quantities of gasoline in the gasoline tank Gasoline tube gasoline filter Normal Abnormal blockage Tube blockage fuel tank evaporation control system Injector clogged Failure of automatic oil ring Blockage Remove...
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Failure of charging (battery overdischarge or overcharge) Fault Diagnosis Adjustment Fault Cause Measuring the voltage at both ends of the battery and starting the motor Out of battery life No voltage rise The battery voltage rises to normal, and then of battery restores to the original Failure of battery...
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No sparking of spark plug Fault Diagnosis Adjustment Fault Cause Replace the spark plug and reinspect No or weak Strong Failure of original spark plug sparking of sparking spark plug Inspect the spark plug and reinspect Not loose Loose Spark plug Check whether the ECU assembly plug is loose Normal...
Inspection/Adjustment Service data Front/rear brake stroke Periodic maintenance schedule chart Wearing of front/rear brake shoe Engine oil/ oil screen Headlamp Fuel filter clutch Inspection/adjustment of throttle cable Front/rear suspension system cleaner Bolt/nut/fasteners Spark plug Wheel rim/tire Battery Tire specification Trottle Steering stem bearing and handlebar fixation Cylinder pressure Drive chain...
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Stroke of rear brake 10-20mm handle pedal Pneumatic pressure unit Front 100/90-18 Front wheel 225kpa of tire: Kpa wheel pneumatic spec. pressure BX125 Rear 120/80-17 Rear wheel 225kpa wheel pneumatic spec. pressure Front wheel 75-85 N·m Rear wheel shaft nut 75-85 N·m Torque...
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gearbox oil Lubrication of all the Lubricant injector places on the vehicle Exhaust pipe Common tool Ignition timing Timing light Throttle Every 10000km: I Tachometer, CO HC Idle exhaust gas analyzer inspection Common tool Throttle inspection Fuel hose inspection Common tool Lamps, instrument and Visual multimeter...
Expected Inspection Ignition system—-perform maintenance inspection on obvious and continuous ignition malfunctions, engine on fire, overheated back burning and others. Carbon deposit removal—-obvious underpower, get rid of carbon deposited at cylinder head, piston head and air exhaust system. Piston and cylinder—-When cylinder is over worn or stuck, please replace it. Please go to your local KSR periodically for inspection and adjustment to keep your vehicle in best conditions.
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Attentions When the engine is warm, replace engine oil. The oil can flow out easily. Shut down the engine. Screw off the drain plug at the bottom of crankcase to drain engine oil. When the engine oil is completely drained, put back cleaned drain plug and sealing ring. Refill engine oil to specified level.
Air Cleaner Replace air cleaner. Remove seat cushion Remove the left side cover Remove the screw of air cleaner Remove the bolt of air cleaner Remove the fixed screw on the air cleaner cover Unscrew the air cleaner. Remove the paper element from the air cleaner.
Spark plug Remove the spark plug cap Remove the spark plug with a spark plug socket. KS MOTORCYCLES - http://ksmotorcycles.com...
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Check the burning, contamination and carbon deposits for spark plug. Eliminate with a spark plug eliminator or steel brush in case of occurrence. Check the stroke of spark plug. Stroke: 0.6-0.7mm Spark plug model: D8RTC * Attentions Install the spark plug manually, and then tighten it with a spark plug sleeve.
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Measure the battery voltage between terminals. Fully charged: 13.1V Undercharge: 12.3V *注意 Attentions Voltmeter shall be used for charging-state inspection. Charging Connection method: Positive pole of battery charger is connected to battery positive lead wire; Negative pole of battery charger is connected to battery negative lead wire. Warning! Battery shall be away from fire source.
Throttle Idle speed adjustment * Attentions Perform idle speed adjustment when the engine is warm. Warm up the engine and then adjust idle speed. Run the engine and connect engine tachometer. Adjust the throttle cable lock-screw to specified RPM. Idle speed RPM: 1400±100rpm/min If idle speed RPM is unsteady or idle speed is not smooth when the vehicle is gently accelerated, adjust idle speed and adjust screws again.
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Drive chain slackness The service lift of drive chain depends on the appropriate lubrication, adjustment and maintenance. Improper lubrication, adjustment and maintenance may cause the earlier wearing of drive chain and sprocket. They shall be maintained frequently under the adverse conditions. Stand vertically the motorcycle on the flat ground and ○...
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(2) fractured or broken wheel teeth (3) Loosen fixing nut of sprockets Lubrication of drive chain Select the drive chain lubricating grease in priority. The drive chain lubricating grease may be purchased, or alternated with engine oil or other lubricating oil. Dip the joints of chain links to make the lubricating grease penetrate into chain plate, pin, lining and roller.
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Wearing of front/rear brake shoe Wearing of front brake shoe When stepping on the brakes in the end, check the oil level at oil cup, if the brake fluid level is lower than the arrow in the figure, intermediately replace the brake shoe. Wearing of rear brake shoe When stepping on the brakes in the end, check the brake fluid level at oil cup, if the brake fluid level is lower than the arrow in the figure, intermediately replace the brake shoe.
Front/Rear suspension system Front suspension Grasp the front brake handle and compress upward and downward the front shock absorber to check its actuation. Check if the front shock absorber leaks oil and if the components are loosened. Rear Suspension Compress upward and downward the rear shock absorber to check its actuation.
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Tire specifications Tire pressure Front 100/90-18 225±10kpa tire BX125 Rear 120/80-17 225±10kpa tire When the tread depth of the tire reaches the value in the table below, the tire should be replaced. The minimum tread depth Front tire 1.6mm Rear tire 2.0mm...
I Braking System Maintenance Instruction-------------------1.1 Fault Diagnosis-------------------------------1.2 Front/rear Hydraulic brake-------------1.3 1.1 Maintenance Instructions Precautions on operation * Attentions • Please do not contaminate braking assembly with oil while assembly or disassembly. • Please use specified detergent to clean the braking assembly, or it may reduce braking performance.
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the front shock absorber. Remove the following components from the front shock absorber Front hydraulic brake 1. Brake shoe 2. Front hydraulic brake tube 3. Brake cylinder assembly *注意 Attentions • Please do not contaminate braking shoe assembly with oil while assembly or disassembly •...
micrometer. 1.3.3 Installation Install front wheel. Install the front hydraulic brake tubing and brake cylinder assembly. The braking shoe should not be contaminated by grease. * Attentions A contaminated braking shoe will reduce braking performance and result in brake failure. Tighten the bolt to their specified torque value.
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Remove the following assemblies from the rear wheel Rear brake: 1. Rear hydraulic brake assembly 2. Braking shoe assembly 3. Lining 4, Disc brake bracket 1.4.2 Inspection Check whether the braking shoe is worn out. Replace the braking shoe if necessary. Measure the braking shoe and brake disc, and record the maximum value.
Torque force value: Rear brake disc mounting bolts 15-25N·m Rear hydraulic brake lower pump mounting bolts 25-35N·m Rear hydraulic brake oil pump mounting bolts 7-9N·m Rear axle 75-85N·m Do not contaminate brake shoes and brake discs with grease. If a braking shoe or a brake disc is polluted by grease, clean it with a brake cleaner. * Attentions A contaminated brake shoe will decrease braking performance.
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Front wheel/ front suspension Front wheel Name Name Axle rubber sleeve Roller bearing 6302 Front axle Hub oil seal Speedometer Front brake disc Front wheel assembly Front axle sleeve Front wheel assembly Front disc brake disc lock sheet Front wheel rim Bolt M6×16 Valve nozzle Front axle self-lock nut M14×1.5...
III Front wheel/ front suspension Service Data-----------------------------3.1 Fault Diagnosis-------------------------3.2 Front Wheel-----------------------------3.3 Steering Handlebar---------------------7.4 Front suspension------------------------3.5 3.1 Service Data Precautions Prior to disassembly of the front wheel, use a jack to support against bottom of the motorcycle, and it is important that the front wheels must not rotate reversely when they keep away from the ground.
3.2 Fault Diagnosis 3.2.1 Steering handlebar rotating without flexibility Steering handlebar bearing is faculty. Steering handlebar bearing is damaged Adjusting nut of motorcycle faucet is too tight. Pressure within the tire is insufficient. 3.2.2 Direction not steady ...
3.2.7 Soft front shock absorber Inadequate fluid in the shock absorber Infirm shock absorber spring Low tire pressure 3.2.8 Too hard front shock absorber Inappropriate fluid weight Blocked shock absorber fluid channel 3.3 Front wheel 3.3.1 Removal Support the vehicle bottom to make the front wheel lifted Unscrew the locknut of front axle...
3.3.2.3 Inspection of front wheel bearing Remove the middle lining of front wheel and the oil seal. Inspect rotation of bearing. If the bearing is found not to rotate, it indicates that the bearing is worn or loosened, and it shall be replaced with new bearing.
* Attentions • The bearing must be pressed in a parallel manner. • The bearing oil seal shall be pressed towards outside. 3.3.4 Installation Apply lubricating grease for the oil seal at front wheel. Apply lubricating grease for the gear position and movable position of speedometer. Install the brake disc after the involution of the gear housing assembly of speedometer Attentions •...
Name Name Hexagon socket head bolts Rear-view assembly M6×22 Right rear-view mirror Fixed half cover Left rear-view mirror Left handle seat Right balancer Left handle Right handle grip Left brake handle switch Right brake handle switch Left handle grip Throttle cable Left balancer Handlebar tube...
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Steering stem upper Decorative buckle 2-10 washer Steering stem assembly 2-11 Steering stem cover nut Steering handle clamp Headlight bracket Steering handle holder Screw M6×16 Steering handle holder Front left shock absorber damped adhesive Upper steering Front shock absorber boot Hexagon socket cap head Front shock absorber seal screws M8×30...
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Name Name Axle rubber sleeve Rear hub Rear axle Rear wheel spoke Step bolt M8×25 Rolling bearing 6302 Rear brake disc Hub seal Rear tire assembly Sprocket Rear wheel assembly Sprocket self-lock nut M10×1.25 Rear rim Real wheel left axle sleeve Valve cock Real axle self-lock nut M14×1.5 KS MOTORCYCLES - http://ksmotorcycles.com...
IV Rear Wheel/Rear Suspension Service Data------------------4. 1 Fault Diagnosis---------------4.2 Rear Wheel------------------4.3 Rear Shock Absorber/Rear Swing arm---------4. 4 Drive chain ------------------4.5 4.1 Service Data Precautions Any grease spot is not allowed on the brake disk and brake shoe. Reference Item Standard value (mm) Allowable limit (mm) Rear wheel Longitudinal...
4.2 Fault Diagnosis 4.2.1 Rear wheel wobbling Wheel rim is deformed. Rear wheel bearing is worn. Tire is faulty. Swing arm bearing is worn or damaged. Driving chain regulator adjusts improperly. Tires and wheels are unbalanced. ...
4.3 Rear Wheel 4.3.1 Removal Release the adjuster. Release rear axle nut. Remove rear axle nut, and remove the chain from the sprocket seat. Remove the rear axle. Remove the rear wheel. 4.3.2 Inspection 4.3.2.1 Axle bending inspection Place the axle on a V-seat, and measure eccentricity with a micrometer gauge.
Visually inspect whether the shock absorber is damaged. The inspection items include: ——whether the shock absorber cylinder is bent or damaged ——whether the shock absorber is subject to deformation or oil leakage ——whether the rubber block is worn or damaged ——whether the spring is damaged Inspect whether the rest parts are damaged or worn If necessary, replace the shock absorber...
* Attentions Do not attempt to straighten bent shaft. Clean parts of rear swing arm mounting shaft with a solvent. Check rear swing arm shaft sleeve component and intermediate sleeve and if any damage is found, replace it. 4.6 Drive Chain 4.6.1....
Check the drive sprocket, driven sprocket, if 1/4 ○ teeth ,a is worn, replace the sprocket, and in case of tooth bending, replace the sprocket. Check wheel bearings, if bearing clearance is found in wheel hub or the wheel has an unbalanced rotation, replace the bearings;...
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Maintain the chain looseness within the specified limits. KS MOTORCYCLES - http://ksmotorcycles.com...
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Inspection and Maintenance of Electrical System Charging system KS MOTORCYCLES - http://ksmotorcycles.com...
V. Battery/Charging System Service Data ---------------------5.1 Fault Diagnosis ---------------------5.1 Battery ---------------------5.1 Charging System ---------------------5.1 Voltage/Current Regulator ---------------------5.1 Generator Charging Coil----------------------5.1 Generator Lighting Coil--------------------5.1 Removal of Generator ---------------------5.1 5.1 Service Data Precautions * Attentions 1. The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after discharging, its service life will be shortened and its performance is degraded.
8. Inspect the entire electric load. 9. Quick charging is forbidden except in emergency. 10. During quick charging, the battery must be removed from the motorcycle first and then be charged. 11. While battery is exchanged, please do not use liquid-feeding battery. 12.
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Unstable power Wiring of battery is poorly contacted. Discharging system is of poor contact. Lighting system is of poor contact or short circuit. Failure of charging system Wire connector is of poor contact, short circuit or short line ...
the state of charged battery. 5.3.2 Charging Connection method: Positive pole of battery charger is connected to battery positive pole; Negative pole of battery charger is connected to battery negative pole. Warning! • Battery shall be away from fire sources. •...
If abnormality is found, check if there is short circuit on ignition switch and main wiring. 5.4.2 Charging State Inspection While in inspection, if the battery is fully charged, a multimeter shall be used for the test. Warm up the engine and then install the fully charged battery onto the motorcycle. Connect voltmeter between terminals of the battery.
If the main wiring end is checked as completely normal, check whether the voltage and current regulator plug is in proper contact, and measure the impedance values between the terminals of the voltage and current regulator. * Attentions • Do not touch the metal part of multimeter probe with your finger.
5.8 Generator Removal 5.8.1 Removal Remove the fixed bolts and screws. Remove the left cover. Fix the flywheel with an all-purpose non-adjustable wrench Disassemble the flywheel hold-down nut Take down the flywheel with a flywheel puller Disassemble the fixed key Disassemble the generator wire joint Disassemble the generator stator 5.8.2 Installation...
Align the groove on the flywheel with the fixed key on the shaft * Note If the inner face of the flywheel is magnetic, make sure no any bolt Fix the flywheel using a universal non-adjustable spanner and then tighten the locknut.
7. The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for impedance value of ignition coil are also recorded and judged. 8. Check ignition switch according to the continuity test table. 9. Remove generator and stator on operation instructions. Service data Item Standard Value...
①Tester is wrongly connected. ②Poor ignition switch. ③Poor contact of joint ④Short-circuit or poor contact of bond strap ⑤ Secondary While no high-voltage power Poor charging coil (Peak voltage side supply, high voltage power is measurement) . ⑥ voltage sporadic. Defective trigger (Peak...
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• There are many brands of multimeters with different interior impedance. The values they measured are not the same. Connect a high-voltage shunt or an ammeter with input impedance higher than 10MΩ 10CV to the multimeter. 6.3.1 Primary voltage of ignition coil If an old spark plug is removed and replaced with a good one, ground it with engine.
6.3.3 Trigger * Attentions Inspect when spark plug is installed on the cylinder head and compression pressure is normal. Remove the trigger lead connectors, connect the resistance grade end of a multimeter with the blue-white line, the other end with the green-white line, measure the resistance. Connection mode: see the right figure.
ignition coil cap and negative terminal. Standard value: 4.5-5.5KΩ(±)10%(20℃) 6.5 Trigger * Attentions Trigger inspection can be performed on the engine. Inspection Remove the trigger lead connectors, connect the resistance grade end of a multimeter with the blue-white line, the other end with the green-white line, measure the resistance. Connection mode: see the right figure.
Starter idler shaft OD 7.94mm Tightening torque value Starter motor clutch cap bolt 12 N·m Starter motor clutch locknut 95 N·m 工具 Tools Locknut wrench Universal un-adjustable wrench 7.2 Fault Diagnosis Stator motor cannot run Stator motor runs weakly Starter motor rotates but the engine does not •Broken Fuse •Low battery...
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7.3.2 Disassembly 电刷 Disassemble housing screw, front cover, motor housing and other parts. 7.3.3 Inspection Inspect other component assemblies. Replace with a new one when there is surface partial friction, injuries or burning loss. Commutator shall be cleaned when there is metal particles adhered to its surface.
Install a new washer ring onto the front cover. Align and install the thread-hole of motor housing to the thread-hole of front cover. Tighten housing screws. * Attentions When assembling housing and front cover, armature can work as a magnet to easily pull the front cover up;...
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7.4.3 Starter relay ground loop inspection Remove starter relay connector. Ω Inspect continuity between grey wire of connector terminal and vehicle ground wire. When the starter button is pressed, continuity between grey wire of connector and vehicle ground wire shall be fine. If there is no continuity, inspect starter button continuity and lead wire.
VIII. Bulbs/Switches/Instruments -------------------------------------------8.1 Service Data ----------------------------------------8.2 Fault Diagnosis -----------------------8.3 Headlamp Bulb Replacement -------8.4 Front Turn Signal Lamp Bulb Replacement- Tail Lamp/number-plate lamp/Rear Turning Signal Lamp Bulb --------------------------------8.5 Replacement --------------------------------------------8.6 Instrument ----------------------------------------8.7 Main switch -----------------------------------------8.8 Electric Horn ---------------------------------------8.9 Handle Switch 8.1 Service Data Precautions on operation Remove switches from the motorcycle and perform continuity test.
8.3 Headlamp bulb replacement 8.3.1 Removal Remove the screws to facilitate the removal of the headlight. Remove the connectors. Remove the headlight locking clip to take off the bulb. 8.3.2 Installation Install the light back in the reverse order of removal. 8.4 Replacement of the front turn signal light 8.4.1 Removal...
Loosen the fixing screws. Take off the light. 8.5.3.2 Installation Install the bulb in the reverse order of removal. 8.6 Instrument Remove the front headlight. Remove the meter connectors. Remove the screws Remove the meters. Install the instrument orderly in the reverse order of removal. 8.7 Main Switch 8.7.1 Inspection Remove the headlamp.
8.8 Electric Horn Inspection Disconnect wire to the electric horn. Connect lead wire of horn with the battery. When the electric horn sounds, it indicates the horn is in good condition. 8.9 Handle Switch Screw off mounting bolt on the brake lever and take down the bracket.
Lubricating System Diagram Camshaft hole 2 Camshaft hole1 Cylinder Crank pin Right crank head Main and auxiliary shaft Clutch cover Cylinder body Piston orifice Engine oil filter Engine oil pump Primary strainer Oil pan IX Lubricating system Service Data-------------------------9.1 -----------------------9.2 Fault Diagnosis ----------------------9.3 Engine Oil Pump...
turning the dry friction on the surface into liquid friction between lubrication oil particles, thus mitigating part wearing, cooling down parts with high thermal load, absorbing impact from bearing and the elements and consequently reducing noises, increasing tightness between cylinder ring and wall, and cleaning and taking away foreign matters from surface of parts. Precautions: After engine oil pump is disassembled, carefully clean its parts and purge the surface with high-pressure gas.
9.3 Engine Oil Pump Disassembly Remove the right cover, remove the clutch, remove retainer ring, remove the oil pump gears and oil pump gear transition gears; Remove the fixing pin, remove screws, remove the oil pump cover, and break down oil pump; Assembly Assemble in the reverse order of disassembly.
Cylinder head Name Name O-ring Cylinder head composition Cylinder head left cover gasket O-ring Cylinder head left cover Observation hole cover Hexagon flange bolt Spark plug Crankcase right cover screw Cap nut washer Plain washer (copper) Plain washer Cross recessed hexagon screw Engine temperature sensor Cylinder head seal gasket Metal plain washer...
Service data 10.1 10.2 Fault Diagnosis Cylinder head/Valve 10.3 10.1 Service Data Function of cylinder head: It is used to seal cylinder and form the combustion chamber along with the piston in order to withstand high-temperature and high-pressure combustible gas. Through the valve system, the cylinder head intakes and discharges gas.
10.2 Fault Diagnosis Low compression pressure Bad valve stroke adjustment Valve burned or bent Bad valve base air tightness Air leakage from cylinder head gasket Poor installation of spark plug Abnormal noise in cylinder head Bad valve stroke adjustment Valve spring damaged Too high compression pressure Too much carbon deposits in combustion chamber 10.3 Cylinder Head...
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Camshaft measuring Measure the height of the cam. 进气凸轮轴 Allowable limit: intake: 31.336 mm Discharge: 31.241 mm 排气凸轮轴 配合轴颈 Remove the screws, nuts and remove the cylinder head. Remove the tappet, compress the valve spring with a valve spring compression tool, and remove valve cock clamp..
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Decomposition of valve Name Name E07-1 Single-shield ball bearing E07-10 Valve inner spring E07-2 Camshaft composition E07-11 Valve outer spring E07-3 Valve rocker composition E07-12 Oil seal E07-3-1 Tappet adjustment screw E07-13 Adjusting washer E07-3-2 Valve lash lock nut E07-14 Adjusting washer E07-4 Torsion spring...
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Inspection Clear carbon deposits on the cylinder cover. If the flatness exceeds the allowable limit, place fine sands on a flat board, engage the interfacing surface with the board, and then grind in a “8” shape. 测试规 Measure free length of valve spring. Free length of the inner valve spring: 39mm Free length of the outer valve spring: 41.8mm 游标卡尺...
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测试计 Measure the inner diameter of valve guide. Allowable limit: Intake/discharge: Ф5.03 mm Allowable limit for stroke between valve rod and its guide: Intake: 0.04mm Discharge: 0.09mm Valve Guide Replacement 起子 Attention: If stroke between the valve and its guide, replace the guide.
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After the guide is inserted, trim it with a reamer. 气门铰刀 Attention: Inject right amount of cutting oil when cut with the reamer. The reamer rotates clockwise. Clear carbon accumulated within the combustion chamber and valve, and thoroughly clean the intake and discharge valves.
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Use a 30° cutter to clear 1/4 of external end of race. 30° Use a 70° cutter to clear 1/4 of bottom of race. Remove the cutter and check the processed locations. 70° Use a 45° trimming cutter to grind the race so that it meets the suitable width.
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If the contact is higher part in the valve, use a 32° cutter to lower the race to its minimum height. If the contact is lower part in the valve, use a 60° 接触面高 cutter to raise the valve base to its minimum height. 32°...
XI Cylinder Block and Piston Service Data 11.1 11.2 Fault Diagnosis 11.3 Cylinder Block 11.4 Piston 11.1 Service Data Function of cylinder block: It offers a space for gas compression, combustion and expansion, and guides in piston motion. It also transfers some of heat to surrounding cooling media. Function of piston: 1.Withstand pressure as a result of combustion of combustible mixed gas, and transfer such pressure to the connecting rod to drive the crankshaft.
Oil ring 0.15-0.6 Piston pin end ID 13.990-14.017 14.067 Stroke between connecting rod and 0.010-0.021 0.089 piston pin 12.2 Fault Diagnosis Low compression pressure Piston worn, burnt or broken Cylinder and piston worn or damaged Gasket damaged and air leakage between crankcase and gas Too high compression pressure Too much carbon deposits in combustion chamber White smoke from discharge duct...
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Attentions Do not break or damage the piston ring. Clear the carbon deposits within the piston ring. 活塞 Install the piston ring. 测试规 Measure stroke between the piston ring and its slot. Allowable limit: Ring 1: 0.09mm 推入 Ring 2:: 0.12 mm Remove the piston ring and install the piston rings at the bottom of cylinder.
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Measure piston OD. 90° Attention: Measurement is made at such position as to form 90° with piston pin and around 11mm from the piston skirt bottom. Allowable limit: Φ57.26mm 11mm Inspection of cylinder inner wall scratch and wearing. 测试计 Attentions: Measure cylinder inner diameter at upper, middle and lower positions at 90°...
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Check the flatness of cylinder surface. 直尺 Allowable limit: 0. 05mm 测试规 气缸 Measure connecting rod small end ID. Allowable limit: Φ14.067mm 连杆小端内径 Installation 顶环 。 Install locating pin. 第二环 Apply engine oil on the piston rings and pistons, and install the piston rings at their positions with the 油环...
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Attentions: Install the larger end of the groove at the top of the piston toward the intake valve. Installation of Cylinder Install the gasket and locating pin on the crankcase. Apply engine oil across the cylinder inner wall, piston and piston ring. Care shall be excised to locate the piston ring into the cylinder.
Crankcase Service Data 12.1 12.2 Fault Diagnosis 12.3 Crankcase Clutch 12.4 12.1 Service Data Function of crankcase: It is a bearing component in the engine. It is provided to support the crankshaft, clutch, gearbox, cylinder block and cover, withstand impact from combustion and inertia force due to crankshaft connecting rod mechanism, and it also forms some enclosed spaces (oil-seal and gas-seal).
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12.2 Fault Diagnosis Low compression pressure Air leakage of crankcase Engine overheating Clutch slip Poor lubrication Shifting failure Shift fork breakage or deformation Fork pin breakage Gear detent wear Auto out-of-gear Engaging claw wear, and edges become rounded Transmission mechanism return spring deflation Wear of the spline shaft spline teeth and sliding gear spline groove results in the occurrence of a greater axial force during the working of the gear.
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12.3 Crankcase Removal of crankcase left cover Loosen the starter motor fixing bolts and remove the starter motor. Loosen the left cover fixing bolts and remove the left cover. Use electric or pneumatic tools to loosen the flywheel lock nut. Pull out the flywheel assembly (including star wheel), remove the starter motor idler gear.
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12.4 Clutch 套筒扳手 Disassembly Loosen five pressure plate bolts by diagonal cross. Disassemble the clutch spring, spring gasket, pressure plate, bearing washer, plane needle roller bearing, bearing seat and clutch sleeve. Loosen the clutch lock nut with special tools, then remove the lock nut and washer.
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Inspection Check if there are burrs or damage in the shell components of the clutch, and get rid of them with a file. Replace the clutch if too much such work needs doing. Check whether it is damaged in the dents of the pressure plate and the center bearing support.
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Measure the thickness of the friction disc with a vernier caliper. 厚度 Allowable limit: replace in case of below 2.5mm Measure the flatness of the driven friction disc with a plug gauge. Allowable limit: replace in case of below 0.2mm Measure the thickness of the plane needle roller bearing.
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Name Name Piston ring combination 11-2-4 Oil tube Piston Cross recessed countersunk head screw Retainer ring for holes Lock washer Piston pin Lock nut Crankshaft assembly Rotor cover gasket Woodruff key Hexagon flange bolt Bearing Washer Flat key Wave washer Flat key Balance shaft driven gear combination Crankshaft adjustment shims...
12.5 Gearshift Mechanism Disassembly Remove the brake arm. 止动臂 Remove the shifting positioning plate. Remove the gearshift combination. The removed parts refer to the gear shift assembly. 变档定位板 Disassembly drawing 变档轴组合 Inspection Before dismounting, the gearshift baffle should be flexible, without clamping. Check the wearing of the baffle and the gearshift mechanism.
Unscrew the bolt in the veneer case. Separate the crankcase. Note: do not damage the surface of the case. Remove the left part of the case. 13.6 Crankshaft Connecting Rod Assembly Removal Remove balance shaft assembly crankshaft connecting rod assembly from the right crank case.
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Measure the stroke along X-Y direction of the big end of the connecting rod. Allowable limit: 0.002-0.010mm 连杆大端测量位置 Measure the dislocation of the crank shaft. Allowable limit: 0.03mm Check if the crank shaft is noisy or loose while restoring. Replace it if so. 曲轴轴承...
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Draw out the shifting fork. Remove the gearshift drum. Remove the gearshift fork. Inspection Measure the shifting fork hole OD. Allowable limit: 11.95mm 千分尺 Measure the shifting fork hole ID. Allowable limit: 12.05mm 测试计 - 113 - KS MOTORCYCLES - http://ksmotorcycles.com...
Measure the the shifting fork thickness. 游标卡尺 Allowable limit: 4.7mm Measure the gearshift drum OD. Allowable limit: 35.75mm 锁槽宽度 Measure gearshift drum lock groove width Allowable limit: 7.35mm 13.7 Transmission chamber 副轴组件 Remove the primary shaft assembly. Remove the secondary shaft assembly. 主轴组件...
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Transmission Component Disassembly Name Name Hexagon bolt Gearshift shaft seal Gear shifting cam positioner composition Gearshift shaft assembly Gear shifting cam positioning spring 15-1 Circlip Cross recessed hexagon screw 15-2 Hard steel shim Gear shifting cam positioning plate 15-3 Gearshift shaft return spring Locating pin 15-4 Gearshift shaft composition...
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Inspection Inspect the abrasion at the surface and transmission claw of the gear. 齿面 Replace it in case of severe abrasion or damage. 传动爪 Remove the bearing and oil seals of left and right crankcase. Inspect the damage to bearings and oil seals, replace them if any. Attentions: Abandon the outgoing bearings and replace with new products.
Exhaust System Inspection and Maintenance Muffler Name Name F05-1 Muffler assembly F05-2 Bolt M8×25 F05-1-1 Anti-scald strip F05-3 Oxygen sensor F05-1-2 Muffler hoop F05-4 Bolt M10×1.5×25 F05-1-3 Exhaust pipe gasket XIII Exhaust control system ---------13.1 Exhaust control system Guarantee ---------13.2 Periodical Maintenance Instructions/Ensuring Emissions Standards ----------------13.3 Mechanical Functions of Exhaust control system...
2. Scope of guarantee 1〉Guarantee on the function of the exhaust control system During the service life (15,000 km), it can pass all the periodic and non-periodic emissions control inspection of the government authorities. 3. The following cases are out of the scope of the guarantee. If maintenance services are needed, services from the franchisers or service centers of our company in different places will be available for the customers at a reasonable price.
speeds. Please notice the following items to ensure consistence with emission standards: 1〉Fuel: only E5 or above unleaded gas can be used. 2〉Engine oil: only specified engine oil can be used. 3〉Maintain it according to the instruction in the periodic maintenance table. 4>...
13.4 Catalytic Conversion System 13.4.1 Structure: 13.4.2 Instructions: 1. The function of the converting catalytic is to convert the complete waste gas like HC, CO and NO after combustion to harmless gas like H O, CO and N , etc. and then discharge them. 2.
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Notes: 1: Test it according to the idling testing procedure. 2. Adjust the engine idle speed to the specific value, and test CO/HC in idling. - 122 - KS MOTORCYCLES - http://ksmotorcycles.com...
Common Trouble Shooting Methods--------------------------------------14.4 14.1 Introduction to Electronic Fuel Injection System BX125 adopts small engine EFI system pr26Voduced by Delphi Company, and the system can realize closed-loop control through oxygen sensor. The system is featured by independent fuel injection and ignition control.
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14.2.1.2 ECU appearance 14.2.1.3 Definition of ECU pin J1- Function correspondence table: (GREY) Code Description Code Description J1-1 Idle speed stepper motor A (high) J1-10 J1-2 J1 -11 Idle speed stepper motor A (low) - 126 - KS MOTORCYCLES - http://ksmotorcycles.com...
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Fault indicator (send alarm to the J1-3 J1 -12 Idle speed stepper motor B (high) meter) J1-4 J1 -13 Idle speed stepper motor B (low) J1-5 J1 -14 J1-6 Tachometer (send speed to the meter) J1 -15 J1-7 CAN wire cable (low) J1 -16 Shutdown (diagnostic switch) J1-8...
14.2.1.5 Precautions for ECU operation 1. Do not put the ECU in a high-temperature part, e.g, muffler or engine; 2. Do not put the ECU near water droplets, oil or any liquid; 3. Do not cover ECU with mud or other contaminants, thereby not affecting its heat dissipation performance;...
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14.2.3 Throttle valve 14.2.3.1 Working principles of throttle valve Throttle Valve Throttle valve is mainly composed of main cast body, return spring, accelerator cable, throttle valve position sensor and idle speed control screw. Throttle valve position sensor sends the accelerator opening to the ECU, idle speed control screw can control idle rotational speed and its stability, specifically reducing the speed by decreasing the air volume of bypass channel in clockwise direction and...
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14.2.5.1 Working principles of intake air temperature and pressure sensors Temperature sensor is used to measure the temperature of intake air, and its resistance will change with the air temperature, and its character is the negative temperature coefficient resistance. The sensor is an non-repairable part.
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14.2.8.2 Appearance of ignition coil: 14.2.9 Idle speed stepper motor 14.2.9.1 Working principles of idle speed stepper motor Idle speed control valve is to control the flow area of the bypass airway of throttle valve to adjust the amount of air into the engine, thereby realizing idle speed control. - 132 - KS MOTORCYCLES - http://ksmotorcycles.com...
14.2.9.1 Appearance of idle speed stepper motor 14.2.10 Fuel pump 14.2.10.1 Working principles of fuel pump Electric fuel pump provides 250Kp gasoline pressure along with pressure regulator to the engine, and is mounted at the bottom of gasoline tank. 14.2.10.2 Appearance of fuel pump 14.2.10.3 Fault diagnosis of fuel pump 1.
14.2.10.4 Common faults of fuel pump The plug of fuel pump assembly is reversely connected, leading to contra-rotation of fuel pump, failing to provide enough fuel pressure to the engine, and making the engine not work properly. Fuel pump is damaged and cannot rotate. 14.2.10.5 Precautions for fuel pump operation The fuel tank of new car has not gasoline, and fuel pipe has a a lot of air after gasoline feeding, so it is necessary to start up the engine for many times to discharge the air in fuel pipe, and then the...
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injector in front cylinder has faults), the indicator will continually flash out the fault code P0201 3.2 seconds after flashing out P0107. If no other fault codes, the indicator will circularly flash out P0107 and P0201, and find out the fault as per the List of Fault Codes. If PCHUD software is adopted, it will report the fault code with decimal numbers, the decimal system in the List of Fault Codes is one-to-one correspondent to the hexadecimal system and the fault can be found out according to the corresponding relationship.
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(4)Select "Parameter File" under "Setup", then click "MT05common.par", and then select "Comm protocol" under "Setup", select "Keyword2000" and click "Ok", and select 17 under Device Code at the same time. - 136 - KS MOTORCYCLES - http://ksmotorcycles.com...
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(5)If the software interface cannot display communication data after the computer is powered, it is necessary to conduct the following work: inspect whether COM port is correctly arranged in the state of "Setup" (generally set as COM Port: 4. Baud Rate: 10400; don't select "DTR high at startup"), Then the software interface will recover communication, display current fault code at "MALFCURR"...
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Schedule 1: Interpretation of PCHUD Software Parameters VRPM engine speed VTHROT throtle position VBARO BARO VMAP manifold air pressure VMAPEXP expect manifold air pressure VIGN ignition key voltage VCLTS cylinder temperature or coolant temperature VIAT intake air temperature STATUSBYTE5 STATUSBYTE5 VAFCMET airflow correction met VBAROCMET...
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IAINTEGOFST airflow integral of idle air control valve IACVDSMP desired position of idld air control valve STATUSBYTE2 STATUSBYTE2 FCLCEN1 cylinder 1 close loop correction enable PPDSEBL prime pulse disable FPENABL fuel pump enable FTRNSAES acceleration enrich enter FTRNSDES deceleration enlean enter FTRNSAEDCLOAD acceleration enrich exit FTRNSDEINLOAD...
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P0336 Crankshaft position sensor is interfered. P0337 Crankshaft position sensor has no signal. P0351 Ignition coil of front cylinder has faults. P0352 Ignition coil of rear cylinder has faults. P0562 Electronic fuel injection system is at lower voltage. 1378 P0563 Electronic fuel injection system is at higher voltage.
Diagnosis tester 14.4 Common Trouble Shooting Methods 14.4.1 Maintenance tools Assembly and disassembly of parts and components of electronic control system - common disassembly tools of automotive parts and components; Circuit and electric signal of electronic control system - digital versatile meter (with buzzer); Fault diagnosis of electronic control system and detection of engine working condition;...
14.4.2.2 Step 2 Whether ECU power supply if off - The communication between the diagnosis tester and the system is interrupted after lock switch is turned off. 14.4.2.3 Step 3 The temperature and temperature cycle of coolant liquid can indicate whether the thermostat is working properly;...
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16.4.3.2 Symptom - Startup failure Switch the ignition switch to "ON" gear, and check whether engine fault indicator blinks. Inspect the fuse and ground wire, Check whether ECU patch plug is firmly connected, If not Use the actuator of the diagnosis tester to check whether the light and the line are normal, flash: ...
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Check whether the clearance of crankshaft position sensor is too large. 16.4.3.3 Symptom - Startup failure with exhaust failure Check whether the high voltage wire of ignition coil is loose, Verify whether the ring gear is loose. 16.4.3.4 Symptom - Unstable idle speed Idle speed control Inspect whether the idle speed bypass bolt is screwed properly, generally screwed into 2 system:...
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Check fuel level in fuel tank and fuel filter; Check whether the exhaust system is blocked, e.g., three-way catalytic converter is blocked due to burn fuel or break-up; Inspect fuel path pressure and nozzle; Check whether the fault indicator blinks and whether the reason is that only one cylinder can normally ignite.
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When the temperature is lower than 10℃ and the whole vehicle and engine operate at low speed for a long time, the exhaust pipe may have carbon deposit and become black, which is normal, and will be eliminated after a period of high-speed operation. Optionally, appropriate measures can be taken to make the temperature of coolant liquid of the engine within the range of specified temperature.
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